Cross-web folder for sheet material

ABSTRACT

D R A W I N G A CROSS-WEB FOLDER FOR FOLDING STRIPS OF SHEET MATERIAL SUCH AS A WEB OF PAPER, EITHER SINGLE OR LAMINATED, PARTICULARLY OF THE TYPE HAVING ROWS OF PERFORATIONS EXTENDING TRANSVERSELY ACROSS THE WEB AT EVENLY SPACED INTERVALS UPON WHICH THE WEB IS TO BE FOLDED INTO WHAT IS KNOWN AS A FAN-FOLDED ARRANGEMENT. THE FOLDER PREFERABLY IS PROVIDED WITH COOPERATING CREASING ELEMENTS WHICH SUCCESSIVELY CREASE THE WEB ALTERNATELY IN REVERSE DIRECTIONS WITH RESPECT TO THE PLANE OF THE WEB TO A LIMITED EXTENT, THE CREASES BEING COINCIDENT WITH PERFORATIONS IF THE WEB CONTAINS THE SAME. FOLDING AND GUIDING MEANS ARE PROVIDED TO EFFECT THE FOLDING OF THE WEB ALONG SAID CREASES INTO A ZIGZAG OR FAN-FOLDED CONFIGURATION AND INCLUDING MEANS TO RECEIVE THE FAN-FOLDED ARRANGEMENT AND HOLD THE FOLDED, CREASED EDGES THEREOF AGAINST RETRACTION INTO THE FOLDER WHILE A CONVEYOR PROGRESSIVELY MOVES THE COMPACT PRODUCT OF FAN-FOLDED AND CONNECTED SECTIONS OF SAID WEB AWAY FROM THE FOLDER FOR SUITABLE PACKAGING OR OTHER OPERATIONS.

H. G. FALTIN Feb. 20, 1973 CROSS-WEB FOLDER FOR SHEET MATERIAL 5Sheets-Sheet 1 Filed Dec- 23. 1970 INVENTOR. HANS G. FALTIN Feb, 20,1973 H. G. FALTIN CROSS-WEB FOLDER FOR SHEET MATERIAL 5 Sheets-Sheet 2Filed Dec. 1970 w 9.2. mm

INVENTOR. HANS G. FALTIN Feb. 20, 1973 H. GJFALTIN CROSS-WEB FOLDER FOP.SHEET MATERIAL 5 Sheets-Sheet 3 Filed Dec 23. 19 0 INVENTOR. HANS G.FALTIN BY J,

AT TVORNE Y 5 Sheets-Sheet 4 H. G. FALTlN CROSS-WEB FOLDER FOR SHEETMATERIAL x bk Feb. 20, 1973 Filed Dec. 23. 1970 INVENTOR. HANS G. FALTINBY j 1/, i %//1"/7/\/ yx/ ATTORNEY Feb. 20, 1973 H. 3. FALTIN 3,717,335

CROSS-WEB FOL-DER FOR SHEET MATERIAL Filed Dec. 5 Sheets-Sheet 5 m u ma) a) C) n 01 a) CD 00 O 1 g Q o m g a c c) no (3 on r P- 0) on a) a) a)no N (D LL 0) m w Q qm 3) N INVENTOR HANS G.FALUN ATTORNEY United StatesPatent 3,717,335 CROSS-WEB FQLDER FGR SHEET MATERIAL Hans G. Faltin,York, Pan, assignor to Advance Enterprises, Inc., York, Pa. Filed Dec.23, 1970, Ser. No. 101,041 Int. Cl. E65 45/00 US. Cl. 270-79 28 ClaimsABSTRACT OF THE DISCLOSURE A cross-web folder for folding strips ofsheet material such as a web of paper, either single or laminated,particularly of the type having rows of perforations extendingtransversely across the web at evenly spaced intervals upon which theweb is to be folded into what is known as a fan-folded arrangement. Thefolder preferably is provided with cooperating creasing elements whichsuccessively crease the web alternately in reverse directions withrespect to the plane of the web to a limited extent, the creases beingcoincident with perforations if the Web contains the same. Folding andguiding means are provided to effect the folding of the web along saidcreases into a zigzag or fan-folded configuration and including means toreceive the fan-folded arrangement and hold the folded, creased edgesthereof against retraction into the folder while a conveyorprogressively moves the compact product of fan-folded and connectedsections of said web away from the folder for suitable packaging orother operations.

BACKGROUND OF THE INVENTION In modern business practices, there is asteadily increasing demand for webs of paper and the like which arefan-folded into a zigzag configuration along transversely extendinglines evenly spaced longitudinally of the web. Fan-folded webs of thistype are used in many fields of activity and particularly in print-outarrangements in production departments, accounting and tabulatingfunctions, inventory operations, billing departments and many othersimilar operations. The Web may be either of a single thickness or maybe of a manifold nature, including carbon-backed webs or separate websof carbon paper interleaved between adjacent webs and fastened togetherappropriately or otherwise.

Sheet products of this type primarily are of a disposable nature in thatthey are retained for a limited period of time and then destroyed.Especially in view of the huge volumes frequently consumed byindustrial, commercial, and other business establishments, it isessential that the production cost be maintained at a minimum. Incidentto minimizing such costs, the speed of production is a vital factor.Machines most commonly used to transform rolls of such paper productsinto fan-folded, compact stacks thereof are of the type which feed theWeb downwardly from a roll, for example, to folding mechanism whichincludes creasing means that impose a crease in the web along the lineof perforations when provided in such web.

Many forms of presses or collating machines exist which employ creasingrollers which are arranged in cooperating pairs, one roller having atleast a single trans verse rib thereon and the mating roller, having atransverse slot adapted to be engaged by the rib on the other roller,whereby a web passing between the same will be creased so as to tend toextend in one direction from the plane of the web after moving past thecreasing means. Such creases are in a single direction only with respectto the plane of the web, whereby it can be seen that inasmuch as the webmust be folded successively in opposite directions along the lines ofperforations, for exam- 3,717,335 Patented Feb. 20, 1973 ple, theplacement of such creases to extend in a single direction issatisfactory relative to forming the fold at one side of a stack but thecreases in the web at the op posite side of said stack extend in thewrong direction to be conducive to ready folding along the lines ofperforations at that side of the stack.

A further difficulty existing in the present machines is that thefolded, compact product is formed substantially in a vertical stack andultimately descends to a conveyor which removes the compacted mass as itis formed for transmitting the same to packaging or other operations.Because of the nature of these types of machines, the speed ofproduction is unsatisfactory to meet the increasing demands ofminimizing costs, but because of the aforementioned drawbacks in themachines, it has heretofore not been possible to increase the speed toany appreciable extent, commensurate with producing satisfactory,undamaged products, due to the basic nature of the operating principlesof such machines.

SUMMARY OF THE INVENTION For purposes of overcoming the shortcomings anddifficulties of the existing art of the type to which the inventionpertains, it is the principal object of the present invention to providea cross-web folder for handling either single thickness or multi-plywebs of sheet material, such as paper, and in which means are includedto provide transverse creases in the web, at evenly spaced locationslongitudinally of the Web, the creases respectively and sequentiallyextending in opposite directions with respect to the plane of the web asit moves through the machine, whereby such arrangement of creasesgreatly facilitates the folding of the sections of web betweensuccessive creases into a fan-folded or zigzag arrangement.

It is another object of the invention to provide means in such folderwhich receive the web in such pre-creased condition and feeds the sameto folding and guiding means of an oscillating nature which directs thecreased web successively in opposite directions, coincident with thedirections of the creases in the web, to effect compact folding of theweb into vertically disposed sections tightly adjacent each other. Whenhandling webs which are transversely perforated, the creases aredisposed precisely in coincidence with the rows of perforations andmechanism is provided in the folder to insure this result.

A further object of the invention is to provide means to receive thecreased, folded portions of the web which are formed respectively at thetop and bottom of the compact, horizontally extending stack or row ofvertically disposed web sections, said means being capable of insuringvery rapid reception of said creased, folded portions and holding thesame against retraction While the compact mass of vertically disposedsheets is moved substantially horizontally away from the discharge endof the folder.

Still another object of the invention is to provide said folding andguiding means with a relatively flat chute, having a passage extendinglongitudinally therethrough for purposes of guiding the web, said chutebeing oscillated about a transversely extending axis by drive meanswhich, in effect, waves the exit end of the chute upwardly anddownwardly for directing the successive creases into folded conditionWhile the same are passing to said receiving means.

It is a still further object of the invention to provide rotatable cammeans which are associated with the receiving means and are locatedbetween said chute and such receiving means for purposes of insuringdeflection and frictional feeding of the creased portions of the web,incident to being folded, toward the receiving means which includesvertically spaced projections behind which the creases, when folded, aredisposed by such rotatable cam means.

Still another object of the invention is to provide said receiving meanswith projections that extend toward each other from vertically spacedpositions and having substantially vertically extending shoulders behindwhich the creased folds are retained against retraction after beingsnapped into such position by said aforementioned rotating cam means.

One further object of the invention is to provide efi'icient drive meansfor a product conveyor by which the compact stack of vertically disposedsection of web, after being creased and folded into compact arrangement,are removed from the folder at a speed corresponding to the rate ofproduction of the product, whereby the folded sections are maintainedsubstantially vertically while being moved to packaging operations,storage, or otherwise.

In addition to the foregoing objects, it is a still further object ofthe invention to provide a web folder which, because of providing theforegoing objects, is capable of operating at substantially higherspeeds than folders presently employed in the industry to which thepresent invention pertains. The folder also being of such nature as torequire minimum maintenance, possessing lasting qualities to insure longlife and being capable of being driven, for example, by a printing pressupon which the Web is printed and/or perforated immediately prior tobeing fed to the folder.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a vertical sectionalelevation of a web folder embodying the principles of the presentinvention as seen upon the line 1-1 of FIG. 3 and illustrating exemplaryframe means, vertically foreshortened, by which the folder may besupported upon an operating surface.

FIG. 2 is an enlarged, fragmentary vertical sectional view of theright-hand portion of the web folder structure shown in FIG. 1 andillustrating, somewhat diagrammatically, the guiding and folding meansof the machine by which the creased Web is fan-folded, said figure alsoshowing details of the receiving means for the folded edges of the Web.

FIG. 3 is a top plan view of the web folder shown in FIG. 1 andadditionally illustrating a receiving conveyor connected to thedischarge end of the folder.

FIG. 4 is a vertical elevation of one side of the folder as seen on theline 4-4 of FIG. 3 and primarily illustrates the driving mechanism forcertain elements of the folder which are disposed exteriorly of thatside of the folder.

FIG. 5 is a view similar to FIG. 4 but illustrating the drive means onthe opposite side of the folder as seen on the line 5--5 of FIG. 3,interior components of the folder being illustrated in phantom so as topermit coordination thereof relative to such drive means.

FIG. 6 is a diagrammatic side view of an exaggerated arrangement ofoppositely extending creases formed in the web incident to the samebeing fan-folded into the compact, folded product in which the foldedsections of the web are disposed substantially vertically upon thedischarge conveyor.

FIGS. 7, 8 and 9 successively are fragmentary, largely diagrammaticviews illustrating certain basic positions of the web folding andguiding means incident to the web being acted upon by the rotatable cammeans which insure movement of the creased, folded portions of the webbehind holding means which prevent retractive movement thereof, the webbeing illustrated in said view by a single line.

FIG. 10 is a fragmentary, enlarged vertical sectional view of details ofthe feeding means of the folder as seen on the line 10-10 of FIG. 3.

FIG. 11 is an enlarged, fragmentary vertical sectional view showingdetails of the creasing mechanism of the folder.

DESCRIPTION OF THE PREFERRED EMBODIMENTS It is the principal objectiveof the invention to provide a machine which will fan-fold a web into acompact mass of sections of uniform size which are connected byseparable creases at a speed far in excess of what is possible by usingconventional equipment. To achieve such improved speeds, the basicconcept of the present invention to make all movement of the web beingfolded in directions which will advance the web with no impedance to thegeneral forward movement of the web, including the final movement of thedelivery mechanism upon which the compactly fan-folded mass of productis progressively removed from the machine as it is formed. The detaileddescription of the preferred embodiments of the mechanism to accomplishthis overall objective is as follows:

As is apparent from FIG. 1 in particular, the crossweb folder 10receives and is adapted to handle a web 12 while moving substantially inhorizontal direction. The web, for example, may be received directlyfrom a printing press wherein the web was printed. Under circumstanceswhere the web is provided with longitudinally spaced, transverselyextending rows of perforations, such presses, or other equivalentmechanism, form such rows of perforations in the web prior to the samebeing delivered to the web folder 10. Primarily due to such horizontalhandling of the web, the web folder 10 is capable of operating at nearlytwice the speed of existing crossweb folders. By way of example, thecross-web folder comprising the present invention has been operated tofullest satisfaction for continuous periods at speeds of 1000 ft. perminute and higher, whereas the highest speed of existing known machinesfor cross folding webs of paper is not appreciably in excess of 600 ft.per minute. The characteristics and details of the cross-web folder bywhich this is made possible are set forth below.

WEB CREASING MEANS One feature of the cross-web folder 10 whichcontributes materially to such higher speed of operation is the mannerin which the Web 12 is creased and folded. Referring particularly toFIGS. 1 and 6, it will be seen that a pair of creasing rollers 14 and 16are mounted upon transversely extending shafts 18 and 20. Each of saidrollers are provided with longitudinally extending grooves 22 in theperipheries thereof, said grooves being filled with suitablecompressible material, such as rubber, having a predetermined amount ofyieldability. Said material should be moderately soft for reasons to beexplained. Each roller also is provided with a creasing blade 24, theouter edge of which projects a limited distance beyond the periphery ofthe roller for purposes of engaging the web 12 and forcing it into thestrip of yieldable material 26, as shown in exemplary manner in FIG. 11.Particularly by utilizing strips of material 26 of suitablecompressibility, the web 12 is distinctly creased along a transverseline 28, without damaging the perforations therein.

The yieldable material 26 should be of similar consistency to the typeof rubber strips used at present as sealing strips on automobile doors.The conventional type is a form of sponge rubber. Similar foam resinsmay also be used. The purpose of the strip 26 is to readily receive theindentation or crease formed by the creasing blade 24, Without rippingor tearing the rows of perforations in the web, if present. However, thestrip 26 must be sufficiently resistant to depression that the web willnot be creased along the side edges of groove 22 at the periphery of theroller 16.

The above-described arrangement for creasing the web 12 comprises adistinct improvement over the creasing facilities of current folders inthat in the latter, it is not uncommon for the creasing blade not onlyto form a crease in a specified direction but, in so forming saidcrease, a pair of bends or creases are formed adjacent opposite sides ofthe desired crease, extending in the reverse direction due to forcingthe web against the sharp shoulders of the channel means or the likeinto which the creasing blade extends incident to creasing the web atthe perforations.

In addition to the foregoing improvement, the present invention providesan even far greater improvement by providing each of the rollers 14 and16 with a creasing blade 24 at one location and diametrically oppositethe same, for example, the groove 22 is formed in which the strip ofyieldable material 26 is disposed for co-action with the creasing bladeof the opposite roller. Accordingly, as can best be seen from FIG. 1,when the blade 24 of roller 14 is in engagement with the web 12, it willdispose a crease therein extending downwardly from the plane of the web12, for example. Meanwhile, the blade 24 of roller 16 is idle. However,upon rotation of the rollers 180 in the direction of the arrows shown inFIG. 1, the blade 24 and roller 16 will be brought into engagement withthe underside of the web 12 so as to form a crease in the web whichextends upwardy due to the blade forcing the web into the yieldablematerial 26 of blade 14.

The foregoing result is illustrated in exaggerated manner in FIG. 6,wherein it will be seen that successive crease lines 28, respectively,and alternately, extend in opposite directions relative to the plane ofthe web 12 and thus, define between said creases sections 30 of the web12 which are of equal length and adapted to be folded into compactrelationship, by mechanism described hereinafter, in which arrangementthe sections are disposed vertically. By providing rollers of suitablylarge diameters, one or both may have more than a single pair of bladesand grooves therein.

Means for driving the shafts 18 and 20 and, correspondingly, thecreasing rollers 14 and 16 are described hereinafter, together withfurther details of other elements of the driving mechanism.

It is conceivable that the creasing mechanism described above may beincorporated in a printing press, collator, or other device, from whichthe web which has been partially precreased, as described, may be fed tothe mechanism described hereinafter.

FOLDING AND GUIDING MEANS After the web has been creased in the mannerdescribed hereinabove, it is fed to feeding rollers 32 and 34. Thefeeding roller 32 is unitary and is supported on shaft 36 which isdriven by means to be described hereinafter. A plurality of rollers 34are utilized, as can best be seen from FIG. 3. These are evenly spacedlongitudinally along the feed roller 32 and are individually supportedby springpressed arms 38. The arms are pivotally secured at one end upona fixed shaft 40 to which a plurality of blocks 42 are fixedly connectedfor purposes of supporting shock springs 44 between projections on saidblocks and the upper surfaces of the arms 38, as can best be seen fromFIGS. 4 and 5.

Preferably the pressure rollers 34 have an elastic periphery 46, such asrubber inserts, for purposes of frictionally engaging the web as itmoves between the feed roller 32 and the pressure rollers 34 by means ofwhich the web is fed from the creasing rollers 14 and 16 to the feedchute 48 which comprises a highly important and essential part of thefolding and guiding means of the present invention. When it is desired,however, to relieve pressure upon the web by the rollers 34, such aswhen the web is bein threaded through the machine and otherwise, all ofthe arms 38 may be elevated at the outer ends thereof so as to move thepressure rollers 34 away from the feeding roller 32. This isaccomplished by rotating the eccentric shaft 50 a limited amount bymeans of a handle 52 which is connected to one end thereof. Movement ofthe handle in the opposite direction will restore the pres- 6 surerollers 34 into operative engagement with the feeding roller 32.

The relative positions of the pressure rollers 34 and feed roller 32 arealso shown advantageously in FIG. 10 wherein it is clearly shown thatthe shaft 49 and the blocks 42 thereon are fixed against movement of anykind, while the arm 38 may be elevated a limited amount by the eccentricshaft which extends commonly beneath the arms 38 within appropriateconcave notches 54 provided therefor. In FIG. 10, the arm and handle 52are shown in full lines in the operative, pressure-applying position,whereas in phantom, the arm and handle 52 are shown in phantom and thepressure rollers 34 likewise are shown in corresponding elevatedposition in phantom.

Hereinabove, the mechanism has been described by which the web 12 iscreased, at the separating lines of perforations along lines 28 betweenthe sections 30 of said web, the creases successively and respectively,extending in opposite directions relative to the plane of the web. Inorder to make appropriate use of such creasing to insure rapid andaccurate folding of the web along said creased lines in the directionsinduced by the alternately oppositely directed creases, the folder 10 isprovided with an oscillatable guide member comprising the aforementionedfeed chute 48. In plan view, as seen from FIG. 3, the chute issubstantially as wide as the feeding roller 32.

Preferably the chute 48 is of a composite nature and is formed from apair of similar, spaced sheet metal plates 56, having rounded outeredges to define a guide slot 58 therebetween, as best seen in FIG. 2.The plates 56 are each reinforced by sheet metal channels 60 which aresecured by welding or otherwise to the plates 56. The opposite ends ofthe channel 60 and the plates 56 are suitably connected to end blocks 62of a rectangular nature. Appropriate pivot pintles 64 respectivelyproject in axial direction outwardly from each end block 62 for pivotalconnection to the upper ends of connecting rods 66 which, in preferredform, comprise metal links.

One end of the feed chute assembly 48 is pivotally connected byadditional short shafts 68 which are secured at one end to the innersurfaces of the frame plate 70 by appropriate bolts and the like,applied to circular flanges 72. These are best shown in FIGS. 4 and 5.The lower ends of the connecting rods 66, respectively, are connected tocrank pins 74 carried by short shafts 76, which are mounted respectivelyand separately in bearings 78 that are fixed to the inner surfaces ofthe frame plate 70 and project toward each other. The shafts 76 projectthrough suitable openings in the frame plate for connection to drivingmembers described hereinafter.

From the foregoing, it will be seen that as the crank pins '14 at theopposite sides of the frame of the folder rotate unidirectionally andsimultaneously, the feed chute 48 will be oscillated about the axes ofits supporting shafts 68, while the outer end thereof oscillates rapidlyupwardly and downwardly. Due to the fact that the web 12, which has beenindented with the creases 28 therein, is rapidly fed by the rollers 32and 34 through the guide slot 58, the emerging web actually is waved orthrown upwardly and downwardly as the chute 48 oscillates. However, suchwaving of the web is in precisely timed relationship to the arrival ofthe various creases 28 therein so as to direct the upwardly extendingcreases upwardly and the downwardly extending creases downwardly toeffect the actual final folding of the creased portions of the web. Saidcreased portions are received by receiving and holding means, details ofwhich will now be described.

RECEIVING AND HOLDING MEANS Referring particularly to FIGS. 1, 2 and7-9, said receiving and holding means comprise a pair of similarcomb-like plates 80 and 82. The opposite ends thereof are secured byappropriate bolts 84, respectively, to the inner surfaces of the frameplates 70 of the folder 10. The

plates 80 and 82 are substantially in vertical alignment with each otherand each of them are provided with projections 86 that have retainingshoulders 88 thereon. The projections 86 also have sloping guidesurfaces 90 which merge into the shoulders 88. It also will be seen thatthe projections 86 extend toward each other and are substantially invertical alignment.

Referring particularly to FIGS. 7, 8 and 9, wherein the actual operationof fan-folding the web is illustrated in relatively simple diagrammaticmanner, it will be seen that as the feed chute 48 swings upwardly to thefull extent of its movement and has commenced to move downwardly asindicated by the directional arrow in FIG. 7, the section 30 of the Webwhich is emerging from the chute has its outermost folded crease 28 inposition to be disposed behind the shoulder 88 of upper plate 80,whereas the folded crease 28 at the lower end of said bowed section 30has been disposed behind the shoulder 88 of the lower plates 82.

To insure the final positioning of the aforementioned upper creased fold28 immediately behind the retaining shoulder 88 of the upper plate 80,the folding and guiding means includes a pair of rotatable camassemblies 92 and 94, each of the cams of said assemblies including apair of similar lobes 96 which comprise spiral cam surfaces whichterminate in peaks 98.

From the directional arrows shown in FIGS. 79, it will be seen that theupper cam assembly 92 rotates counterclockwise, while the lower camassembly 94 rotates clockwise. It also will be seen from FIG. 7 that thelower lobe 96 of cam assembly 92 is nearly in position to engage theuppermost creased fold 28, which is ready to be disposed behind theshoulder 88 of upper plate 80 and thereby insure the accuratepositioning of said folded crease behind said shoulder for retention bysuch shoulder against retractive movement. The stiffness of the sections30 of the web also is sufficient to permit the initially bowedconfiguration of the outermost web 30 shown at the left portion of theassembly in FIG. 7, to straighten and be disposed compactly against thepreceding, connected and folded sections 30 of said web.

As best shown in FIG. 2, the upper and lower plates 80 and 82 areslotted from the left side, inward, as viewed in said figure, toaccommodate the individual cam members of each of said assemblies 92 and94. Referring to FIG. 3, it will be seen that the individual cam members100 are all identical and are formed from a suitable thickness of sheetstock of non-metallic material, such as a very dense type of fiberboardimpregnated with synthetic resin. Such material is capable of impartingfrictional feeding movement to the web. The individual cam members arealso centrally 'apertured so as to be mounted respectively upon an uppershaft 102 or a lower shaft 104. Spacers 106 are disposed upon the shaftsbetween each of the individual cam members 100. Due to such arrangementof spaced cam members, a series of parallel strips or webs may be fedsimultaneously by said machine and each strip or web will be similarlyfed and folded.

The components of the assemblies are compressed firmly against eachother upon the shafts in an axial direction to secure the individual cammembers 100 in accurate position longitudinally. To prevent rotation ofthe same relative to the shafts, key means 108, shown in FIG. 2, areemployed. For practical purposes, therefore, the individual cam members100', when assembled upon the shafts, all act as a unitary assembly 92and 94. Due to the fact that the cam members 100 are required to snapthe creased folds behind the retaining shoulders 88, however, it isessential that the plates 88 and 82 be provided with slots which areidentified by dotted lines 110, shown in FIG. 2, to accommodate the cammembers. From the upper portion of FIG. 2 in particular, it will be seenthat the peaks 98 of cam members 100 will move the creased fold past theshoulders 88 to effect firm final creasing of the sections into acompact mass.

When the peaks 98 have moved out of engagement with the creasedsections, the mass will move backward toward stops 88, but sucharrangement effectively forms the final creases in the product mass.

- DESCRIPTION OF FINAL CREASING Referring to FIG. 8, it will be seenthat the feed chute 48 is substantially horizontal and thus, hastraversed approximately one-half of its path of movement from theuppermost position thereof, shown in exemplary manner in FIG. 7, and thelowermost exemplary position thereof shown in FIG. 9. In this figure,the bowed, outermost section of the web 30 has not completelystraightened while moving in feeding direction, without impedance, sothat the uppermost creased fold has been disposed fully behind theshoulder 88, while the next outermost section 30 is being formed by thelowering movement of the chute 48. The final disposition of theuppermost creased fold 28 behind the shoulder 88 will immediately beeffected, however, due to the lobe 96 being substantially in position tofrictionally contact the uppermost creased fold and feedingly move itinto full insertion behind the upper shoulder 88. As a final insuranceof such positioning, the oncoming peak 98 of the uppermost cam assembly92 will provide the final pushing movement to dispose said uppermostcreased fold as aforesaid with respect to shoulder 88. The guidesurfaces 98' on the projections 86, in conjunction with the over-travelof cam peaks 98, also facilitate the final disposition of the creasedfolds behind the shoulders 88 with respect to both the upper and lowerplates 33 and 82.

In FIG. 9, the chute Si) is illustrated in exemplary manner as havingjust reached the lowermost position and is commencing to move upwardlyagain as indicated by the directional arrow 112. As a result, it will beseen that the outwardly bowed, outermost section 30 of the web does nothave its lower creased fold 28 fully disposed behind the lower shoulder88 due to the shortening eifect produced by the bow in the outermostsection 30 shown at the left of the fragmentary exemplary illustrationof fan-folded assembly of sections. However, upon the adjacent lobe 96of the lowermost cam assembly 94 being in position to engage thelowermost creased fold 28, the latter will be disposed fully behind theshoulder 88 of lower plate 82, while a new, oncoming section 30 of theweb is being formed to extend upwardly as the chute moves to itsuppermost position which is illustrated in exemplary manner in FIG. 7.

From the foregoing, therefore, it will be seen that the rotatable camassemblies '92 and 94 not only effect the final feeding and positioningof the creased folds 28 of the connected web sections 30 behind thereceiving means which primarily comprise the vertically disposedshoulders 88 of projections 86 which extend toward each other fromplates 8% and 82, but the over-travel of the peaks 98 of the cam memberseffect final firm creasing of the folds which connect the sections ofthe web. Further, in the various views and especially FIGS. 1, 2 and 79,the fan-folded sections 39 are shown in expanded manner, primarily toillustrate the individual sections in a visual manner. In actuality,particularly due to the weakening provided by the perforations betweenadjacent sections 30, when they are placed in fan-folded web formationof this type, as soon as each new section 36 has been deposited acrossthe nearest section of the horizontal stack of vertically disposedsections 30 and the connecting creased fold 28 thereof has been lodgedbehind the retaining shoulders 88 to prevent retractive movementthereof, such assembly of fan-folded sections 30 is very compact.

To achieve such foregoing arrangement, when operation of the cross-webfolder 10 is initiated, it is necessary that an operator manually assistin positioning the first few folded sections so as to dispose themvertically in non-retractive position behind the shoulders 38. This canbe done by holding a sheet of cardboard or the like in vertical positionso as to be abutted by the first few sections 30 as fed from the chute48. A carton or other light weight means also may be used to effect suchabutment for initial positioning of the fan-folded section and, as astack of the same forms in a horizontal direction of compactedvertically disposed sheets or sections 30', the formation of such stack,in compact manner, from then on is effected automatically. Means bywhich the corn pact assembly of fan-folded sections 30 is removed fromthe machine is as follows:

DISCHARGE MECHANISM Referring particularly to FIGS. 3-5, it will be seenthat a rectangular frame comprising side plates 114, which are parallelto each other, are connected to frame plates '70 of the main frame ofthe folder by any suitable bracket means, not shown. The side plates 114may be of any suitable length. In the opposite ends thereof, appropriatebearings are formed for purposes of receiving the opposite ends ofcylindrical shafts 116 and 118. A plurality of narrow endless belts 120extend around the shafts 116 and 118. Such assembly of belts constitutesa receiving conveyor for the compact assembly of fan-folded sections 30of the web 12 and upon which said sections are disposed in substantiallyvertical position upon such horizontal conveyor.

The conveyor is driven at a relatively slow speed due to the fact thatthe compact arrangement of fan-folded, relatively thin, web sectionsbuilds up rather slowly, notwithstanding the fact that the web 12 may bemoving through the creasing and folding portions of the folder 10 at ahigh rate of linear speed, such as of the order of 1000 ft. per minute.In view of this, it is found convenient to utilize roller 116 as thedrive roller for the conveyor. One end of a ratchet arm 122 is fixed toone end of the drive shaft 116 for the conveyor. Said arm preferably isprovided with a longitudinal slot 124 within which one end of anadjustable pintle 126 is adapted to be secured in a desired position.Any form of conventional ratchet mechanism, not shown, such as a one-wayclutch may be disposed between the lower end of lever 122 and the driveshaft 116. Also, to prevent retractive movement of the conveyor whenlever 122 is retracting, another reversely directed one-way clutch 123is connected to drive shaft 116, as seen in FIG. 3.

A connecting rod or link 128 is connected at one end to the adjustablepintle 126 and the opposite end thereof has a pin 130 which connects itto one of the connecting rods 66 by which the chute 48 is oscillated. InFIGS. 4 and 5, it will be seen that the upper end of said connecting rodhas a plurality of holes 132 therein. By selecting one of the holes 132for the disposition of pin 130 therein, it will be seen that a verylimited amount of longitudinal movement of the connecting rod 128 willbe produced for purposes of operating arm 122 and thereby moving thediscarge conveyor, comprising belts 120, at a very slow rate, stepwise,as the driving shaft 116 for said conveyor is moved by the ratchet whichconnects the arm 122 to the shaft 116. Further adjustment may beachieved by moving the adjustable pintle 126 relative to slot 124 andsecuring it in a desired, set position.

Referring to FIGS. 1 and 3, it will be seen that the cross-web folder 10primarily comprises a frame or body which includes a pair of parallelframe plates 70 which preferably are formed from rigid metal, such assteel or aluminum, of suitable thickness. Appropriate crossbars and rods134 and 136- extend between said side plates to secure the same precisespaced relationship. An appropriate supporting frame comprising aplurality of legs 138 depend downwardly from the frame structure and, ifdesired, may be braced by cross-members 140 and also can be renderedportable by utilizing casters 142. For purposes of simplicity, thedischarge frame com- 1G prising side members 114 and elongated rollers116 and 118 are not illustrated in FIG. 1 but it will be understood thatthe same are connected to the righthand end of the folder 10 as shown insaid figure.

DRIVE MECHANISM The means by which the various shafts and other movableelements of the folder 10 are actuated are best shown in FIGS. 4 and 5.It will be seen that these figures re spectively are taken on the lines44 and '55 of FIG. 3. When facing the delivery end of the folder 111from which the conveyor comprising belts extends, it will be seen thatthe drive mechanism illustrated in FIG. 4 is on the left-hand side ofthe machine and the drive mechanism shown in FIG. 5 is on the right-handside of the machine. Considering the direction in which the drive meansis shown along the line 55 of FIG. 3, however, understanding theoperation of the drive means illustrated in FIG. 5 would be diificultunless the means driven thereby also is illustrated in the figure.Accordingly, in FIG. 5, the various elements of the cross-web folder 10are shown in phantom. Said elements are also shown in broken lines inFIG. 4, due to the fact that the elements are behind the left-hand frameplate 70.

Referring to FIG. 4 in which the drive mechanism at the left-hand sideof the folder 10 is shown, a shaft 144 is mounted within suitablebearings provided respectively in the frame plates 70, and actuallycomprises the principal drive shaft of the machine. Momentarilyreverting to FIG. 5, it will be seen that the shaft 144 is provided witha sprocket gear 146, which is illustrated diagrammatically, and aroundwhich a sprocket chain 148 extends, which is connected, for example, toa driving sprocket gear on a printing press, not shown. Accordingly, bymeans of the sprocket chain 148, the operation of the folder 111 is indirect, timed relationship with the output of a printing press sothatthe speed of the press and that of the folder are coincident. Also, sucha press, as referred to hereinabove, is capable of providing thetransverse perforations between the connected sections 30 of the web 10under circumstances where such perforations are desired to be in theweb.

From the foregoing description, it should be apparent that in theoperation of the creasing rollers 114 and 116, in relationship to thefolding of the sections 30 of the web 12 by means of the oscillatingchute 48, cam assemblies 92 and 94, and then the reception of thecreased and folded product by the receiving and holding means comprisingthe plates 80 and 82, it is essential that the various elements of themechanism which produce the final result must operate in precisely timedrelationship with respect to each other. In this regard, in theembodiments of the invention which have been reduced to practice andsuccessfully operated, the timing operations referred to have beenachieved satisfactorily by utiliz ng flexible endless timing belts andcomplementary timing pulleys, both driving and driven, have beenemployed.

Regarding the driving mechanism, it is to be understood that othersuitable, timed-type driving and operating mechanism may be employedsuch as by utilizing sprocket gears and chains, the mechanicalequivalent thereof, or otherwise. Accordingly, in the followingdescriptions, it is to be understood that all of the elements describedare driven by means which comprise timed driving and driven mechanismand it is to be assumed that the same are flexible, endless belts,having transverse ribs thereon which cooperate with driving and drivenpulleys having complementary notches therein but such illustrations areto be considered solely as illustrative, rather than restrictive, aslong as appropriate, timed-type of driving and driven mechanism isemployed.

In FIG. 4, the driving shaft 144 has a driving pulley 150 thereon aroundwhich an endless driving belt 152 extends, the same also extendingaround a driven pulley 154. An idler pulley 156 also is employed fortightening purposes. Driven pulley 154 is connected to shaft 20 to whichan additional driven pulley 158 is connected. An endless, flexibledriving belt 160 extends around pulley 158 and also around a largerdiameter driven pulley 162 which is fixedly connected to the shaft 104to which the lower cam assembly 94 is aflixed.

Shaft 36 upon which the feeding roller 32 is mounted, and to which it isaffixed, has a driven pulley 164 connected thereto and around which anendless driving belt 166 extends, said belt also extending around adriven pulley 168 which is connected to a projecting end of one of theshort shafts '76 that drives one of the crank pins 74 for purposes ofactuating the connecting rod 66 which is connected to one end of thefeed chute 48. All of the aforementioned driving means shown in FIG. 4-are disposed exteriorly of the outer surface of the lefhhand frame plate70. The drive means disposed exteriorly of the right-hand frame plate 70is as follows:

Referring to FIG. 5, as described hereinabove, the drive shaft 44extends between the spaced frame plates 78 of the folder and oppositeends of said shaft respectively project beyond the outer surfaces ofsaid frame plates. Accordingly, on the right-hand side of the folder 10,the drive shaft 144 has a driving pulley 170 connected thereto. Shaft 36of the feeding roller 32 also has a driven pulley 172 connected theretoand an endless driving belt 174 extends around the driving pulley 170and the driven pulley 172. A tightening idler pulley 176 also engagesone course of the belt 174. Thus, it will be seen that the feedingroller 32 is directly driven by the main drive shaft 144.

The driven pulley 172 actually is a double pulley and the second portionthereof has a driven belt 178 extending therearound. Belt 178 alsoextends around a larger diameter driven pulley 180 which is fixed to theshort shaft 76 to which the crank pin 74 is connected for driving theconnecting rod 66 at the right-hand side of the folder 10. Theconnecting rod 66 connected thereto will actuate the right-hand end ofchute 48 in unison with the drive means for the above-describedleft-hand side of the folder 10.

The shaft which supports the lower creasing roller 16 has a spur gear182 keyed thereto for engagement with a driven spur gear 184, which isconnected to one end of a short shaft 186. A driving pulley 188 also isfixed to said shaft in direct overlying relationship with respect to thespur gear 184. A flexible, endless driving belt 190 extends around thepulley 188 and also around a driven pulley 192 which is connected to oneend of shaft 18 upon which the upper creasing roller 14 is connected.The pulley 192 is a double pulley and the other element thereof hasanother endless, flexible belt 194 extending therearound and also arounda larger diameter driven pulley 196 which is connected to the shaft 182upon which the upper cam assembly 92 is affixed.

ilt also will be understood that the various shafts referred tohereinabove with respect to the description of the driving means projectthrough appropriate openings and holes formed in the frame plates '70through which said shafts project. Suitable bearings are connected tothe frame plates for purposes of supporting such shafts. Theconstruction thus described results in providing a very compact andrelatively simple type of cross-Web folder which is of sturdy and ruggedconstruction and is capable of sustaining the high speed at which itoperates eificiently with a minimum consumption of power commensuratewith the improved result capable of being produced by the folder incomparison with current results of existing fan-fold type folders.

The increased speed of the folder comprising the present inventionprimarily is due to substantially smaller diameter of the creasingrollers and the manner of handling the web essentially in a horizontaldirection until it reaches the folding and guiding means which directlydeliver the creased, and at least partially folded, web to the receivingmeans which finalizes the folding of the webs into a compact dispositionof the successive sections of the web in vertical condition for movementhorizontally along a discharge conveyor. There are no appreciablelengths of the web between individual operating elements of the machine,thereby further contributing to the compactness thereof.

In addition to the simplified construction, which contributes materiallyto the minimum manufacturing expense, all elements of the folder arereadily available for adjustment and such limited servicing as themachine requires from time to time as a result of the high speedoperation thereof.

While the invention has been described and illustrated in its severalpreferred embodiments, it should be understood that the invention is notto be limited to the precise details herein illustrated and describedsince the same may be carried out in other ways falling within the scopeof the invention as illustrated and described.

I claim:

1. A cross-web folder comprising a pair of rollers adapted to receive acontinuous elongated web of foldable material therebetween, cooperatingcreasing means on said rollers operable to indent transverse successiveprefold creases in said web which alternately and respectively extend inopposite directions relative to the plane of said web to define sectionsthereof, a feed chute positioned to slidably receive said creased Webfrom said rollers and discharge the web from one end thereof, means tooscillate said one end of said chute in directions to dispose saidsections of said web generally in zig-zag arrangement while moving awayfrom said chute in at least partially folded condition at said creasesin said web, folding and guiding means extending parallel to the creasesof said web and including rigid rotatable means extending transverselyacross the path of said web substantially for the full width thereof andpositioned to frictionally engage said creases therein and increase thefolds of the Web along said creases throughout the length thereof todispose the sections of said web in fan-folded arrangement, andstationary shoulder means fixedly positioned to receive the folded edgesof said fan-folded web and hold the same against retracting movement assuccessive folded edges are presented to said receiving means by saidfolding and guiding means.

2. The folder according to claim 1 in which the axes of said rollers arein a common substantially vertical plane and receive said webtherebetween and said stationary shoulder means to receive folded edgesof said fan-folded web are spaced apart vertically and are operable tohold the folded sections of said web in substantially vertical position.

3. The folder according to claim 2 further including a substantiallyhorizontal conveyor positioned to receive said fan-folded Web andincluding means operable to progressively move the same away from saidreceiving and holding means as the folded web sections are formed and ata speed adapted to maintain said sections substantialiy in compactarrangement against each other.

4. The folder according to claim 2 in which said fixedly positionedmeans to engage said folded creases comprise projections extendingtoward each other and positioned to receive the folded edges of said Webas they are snapped past said projections by movement imposed thereon bysaid folding and guiding means.

5. The folder according to claim 1 in which said folding and guidingmeans comprise rigid rotatable cam members adapted to engage said Webwith a wiping frictional contact operable to move the creased folds ofsaid web toward said receiving and holding means.

6. The folder according to claim 5 in which said receiving and holdingmeans comprise projecting shoulders positioned adjacent said rotatablecam members, and the wiping engagement of said rotatable cam memberscause said creased folded portions of said web to be snapped behind saidshoulders.

7. The folder according to claim 6 in which said rotatable cam memberswhich engage said web have rounded lobes comprising cam surfaces whichslidably engage said web during the operation thereof.

8. The folder according to claim 7 in which said lobes have peakedportions which cause final snapping action when engaging said creasedand folded portions of said web to complete the disposition of the samebehind the shoulders of said receiving and holding means.

9. The folder according to claim 6 in which said rotatable cam memberscomprise a series of similar cam members fixed to and transverselyspaced along rotatable shafts, and said receiving and holding meanshaving slots aligned with and adapted to permit passage of portions ofsaid cam members therethrough to insure positioning of said creasedfolds of said web in holding position by said receiving and holdingmeans.

10. The folder according to claim 9 in which said cam members have lobesand peaked portions and said receiving and holding means have shoulders,said slots in said receiving and holding means extending therein to adepth adjacent said shoulders to insure snapping of said creased foldsof said web behind said shoulders by peaked portions of said cammembers.

11. A cross-web folder including in combination:

(a) means to receive an endless web of foldable sheet material andindent successive alternately reversely extending creases therein atevenly spaced intervals,

(b) means to feed said creased web along a substantially horizontalpath, v

() means to wave the sections of said web between said creasesrespectively upwardly and downwardly while permitting longitudinalmovement of said web through said means to permit said sections to befolded in the directions in which said reversely extending creases areinclined,

(d) rotatable rigid cam means positioned respectively above and belowsaid path of said web as it moves from said waving means and extendingacross said web substantially parallel to said folds in said web, saidcam means being positioned to wipingly engage said folds to positivelyincrease the folded extent thereof, and

(e) stationary shoulder means spaced apart substantially vertically andpositioned adjacent said cam means and adapted respectively to engagesaid creased folds of said web and prevent retractive movement thereof,whereby the entire movement of said Web moves continuously substantiallyin advancing direction free of impedance to permit high speed operationof said folder.

12. The folder according to claim 11 in which said stationary shouldermeans are fixedly positioned substantially within a vertical planeadapted to engage and hold the foldable connected sections of said Webin substantially vertical position, whereby compact disposition of saidsections is eifected.

13. The folder according to claim 12 further including a substantiallyhorizontal conveyor positioned adjacent said spaced engaging means andoperable to receive the vertically disposed sections of said folded webafter the same have been disposed behind said spaced engaging means andas the same progressively move away from said engaging means incident tosuccessive creased folds being disposed behind said means.

14. The folder according to claim 13 further including mean connected tosaid conveyor and operable to drive the same at a speed adequate tomaintain the folded sections of said web in compact fan-foldedsubstantially vertical position.

15. The folder according to claim 14 in which said drive means for saidconveyor comprises a ratchet lever, and drive means operated by saidmeans which wave the sections of said web between said creases connectedto said ratched lever to operate the same.

16. The folder according to claim 12 in which said spaced engaging meanscomprise substantially vertical shoulders behind which said creasedfolded sections of said web are disposed.

17. The folder according to claim 16 in which said rotatable rigid cammeans are positioned to closely precede said spaced shoulders, saidrotating cam means being operable to snap the folded creased portions ofsaid web behind said shoulders in a direction to effect discharge of thefolded web from said folder.

18. The folder according to claim 17 in which said cam means comprise anassembly of similar rigid cam members spaced apart along rotatableshafts and said assembly subtending substantially the entire width ofsaid web, said cam members being provided with spirally curved surfacesterminating in a peak to provide final pushing action of the creasedfolded portions of said web to insure disposition thereof behind saidshoulders.

19. The folder according to claim 18 in which each of said cam means hasa plurality of spiral cam surfaces terminating in peaks comprising thehighest portions of said cam surfaces and respectively spaced equallycircumferentially around said cam surfaces.

20. The folder according to claim 17 in which said shoulders are formedon projections respectively extending toward each other and spacedvertically apart, said projections also having sloping relief surfaceson said projections engageable by said creased folded portions of saidweb incident to being snapped behind said shoulders and operable toguide said creased folded portions into contact with said shoulders.

21. The folder according to claim 11 in which the means to feed saidcreased web comprises a feed roller in a series of axially alignedpressure rollers peripherally coacting with said feed roller to eifectfriction feed gripping of the web to move the same through the folderand direct the web into the means to wave the web between the creasesthereof.

22. The folder according to claim 21 further including spring pressedmeans operable upon the pressure rollers, said pressure rollers beingsupported by arms pivotally supported at one end and the folderadditionally including means operable simultaneously to engage said armsand move said pressure rollers at least a limited distance away from theperiphery of the feed roller when desired.

23. A cross web folder adapted to receive a continuous elongated web offoldable material comprising a series of connected sections which hasbeen at least partially creased alternately in opposite directionsrelative to the plane of the web between adjoining sections thereof,said folder comprising in combination, feed means adapted to engage saidweb and move it longitudinally at a substantial predetermined speed,means adapted to guide and oscillatably move successive sections of saidweb alternately in opposite directions relative to an axis extendingtransversely to the path of movement of said web, a pair of rigidrotatable cam means extending across substantially the full width ofsaid web adjacent opposite surfaces thereof and respectively operable tofrictionally engage said sections of said web while moving in saidopposite directions to advance said sections into fan-foldedconfiguration upon said creases in said web and eifect at least partialfinal creasing of said sections into compact fanfolded configuration,and receiving and holding shoulder means mounted stationarily above andbelow the path of movement of said configuration of said web and adaptedto receive the at least partially creased edges between adjacentsections of said web as the same are advanced thereto by said rotatablecam means to hold said folded sections and finalize the creases betweensaid sections by compacting the oncoming sections against the previouslyfolded sections.

24. The folder according to claim 23 in which said web is fed in agenerally horizontal direction by said feed means and said feed meansand rotatable cam means being operable to deflect said sections of saidweb alternately upwardly and downwardly to dispose said sections intosubstantially vertical position, and said receiving means being adaptedto retain said folded sections in said substantially vertical position.

25. The folder according to claim 24 further including conveyor meansadapted to receive said folded sections in substantially verticalarrangement and move the same in a substantially horizontal directionaway from said receiving and holding means at a speed adapted tomaintain a compact bulk of folded sections adjacent said receiving andholding means to permit said rotatable cam means to press the oncomingsections into final folded condition as the same are received by saidreceiving and holding means.

26. The folder according to claim 25 in which said rotatable cam meanscomprise an assembly of similar cams having peaked portions and saidreceiving and holding means comprising vertically spaced shoulderspositioned adjacent the rotary paths of said peaked portions of saidcams and adapted to be engaged by the finally folded edges of adjacentsections of said Web as moved behind said shoulders by said peakedportions of said cams.

27. The folder according to claim 26 in which said peaked portions ofsaid cams are of sufiicient height in a radial direction to push saidfinally folded edges which connect adjacent sections of said webslightly beyond said shoulders to effect firm final folding and creasingof said edges, followed by limited relaxing of the pressure on saidcompact mass of folded sections when said peaked 16 1 1 portions of saidcam move from engagement with said sections of said web.

28. The folder according to claim 23 in which said rotatable cam meanseach comprise an assembly of similar plate-like cam members spaced in anaxial direction from each other upon a rotatable shaft, said cams beingsimilar in shape and aligned in an axial direction to functionsimultaneously, said assembly being substantially as long as the Widthof said folder, whereby a plurality of striplike webs of material may befed by said folder and similarly handled in parallel manner by said cammembers.

References Cited UNITED STATES PATENTS 3,547,430 12/1970 Assony 270 792,359,417 10/1944 Hand 270 73 3,579,248 5/1971 McGrath,Jr 270-6113,406,959 10/1968 Ross 270 73 3,006,634 10/1961 Lawrence et a1 270-73FOREIGN PATENTS 6411421 4/1965 Netherlands 270-79 ROBERT W. MICHELL,Primary Examiner L. R. OREMLAND, Assistant Examiner US. Cl. X.R. 27161 F

